Retrofitted boiler apparatus and method for making same

ABSTRACT

Retrofitted boiler  10  includes a coupling flange  60  and a door  68  mounted in a boiler chamber  14.  A high efficiency burner  80  is coupled in the door  68.  Door panels  82  are provided to cover door openings  72.  This allows access to the inside of the boiler  10  and provides maximum efficiency. 
     The boiler retrofitting method requires removal of doors  18  and  34.  A gas manifold  40  is modified and insulated with insulation  54.  A coupling flange  60  is positioned in the boiler  10  and door  68  is coupled thereto. A high efficiency burner  80  is coupled in a boiler door opening  74   adjacent the modified gas manifold  48.  Door panels  82  are then coupled to the door  68  to cover openings  72.  With the boiler  10  retrofitted with a single door  68,  a much more efficient boiler is provided.

TECHNICAL FIELD

This invention relates to a boiler apparatus and more particularly to a retrofitted boiler apparatus for increasing the efficiency of a boiler's operation. The boiler's efficiency is determined for the most part by the active element of the boiler, the burner. The more efficient the burner, the smaller the amount of fuel needed to operate the boiler. Of course there is a direct relationship between the fuel necessary to operate the boiler and the air needed to burn the fuel efficiently. The idea is to strive for the perfect fuel to air ratio. In certain types of boilers that means eliminating excess air which can result in an inefficient use of heated air in the boiler system. That is excess air should be eliminated where ever and whenever possible.

BACKGROUND OF THE PRIOR ART

In some of the existing and commonly used boilers operational access to a combustion chamber or baffle plate area of the boiler is through an access point having a pair of access doors. An inside door is aligned adjacent front baffle plates of the boiler and a front or outside door is spaced from and aligned adjacent to the inside door.

This boiler design causes an air cavity to be created between the front and inside doors of the boiler. It is in this area where the fuel and air mixture is managed by a fan and burner fitted into the front door of the boiler. Because of this design excess air is generated in the air cavity of the boiler resulting in an inefficient use of heated air in the air cavity. That is the fuel to air ratio is affected significantly resulting in reduced boiler efficiency. In addition to the problems created by the air cavity, the doors of the boiler are heavy and cumbersome, making boiler access difficult. Because of the size and weight of the doors they require that their gaskets be frequently changed to minimize boiler leaks that affect the efficiency of the boiler.

Boilers of this type are widely used in the industry today. Because of the widespread use of this kind of boiler there is an ongoing need to manage the fuel to air mixture more efficiently.

The technologies that have been utilized to address that problem for the most part have been concerned with providing a boiler design having a higher efficiency burner. That is, a burner with the fan and air manager built in thereby creating a much higher level of efficiency in the fuel and air burner mixture. It does not require a burner and a separate a fan which manages the fuel and air in an air cavity to sustain boiler operation. Thus retrofitting existing boilers so that the air cavity is eliminated by providing the boiler with a single door that would be aligned adjacent to and fit up against the front baffle plate area of the boiler so that the high efficient burner can be utilized and so that the problems associated with the two heavy doors of the existing boiler are eliminated, is desirable.

DISCLOSURE OF THE INVENTION

A retrofitted boiler apparatus is provided. The apparatus of this invention includes a boiler chamber having a longitudinal extending opening formed therein. An internal combustion cylinder is aligned in the boiler chamber. A plurality of fire tubes are provided which surround the combustion cylinder. A coupling flange is supported in a frontmost portion of the opening in the boiler chamber. A boiler door having a plurality of spaced aligned openings formed therein is aligned adjacent the coupling flange so that predetermined portions of the opening in the boiler chamber can be selectively covered. A means is aligned in and coupled to the boiler door in a lower opening of one of the plurality of openings in the boiler door for directing a predetermined fuel and air mixture into the boiler chamber to form hot combustion gases in the combustion cylinder so that the fire tubes are activated to facilitate the operation of the boiler. Additionally, the retrofitted boiler is provided with first and second door panels which are pivotably coupled to the boiler door to selectively cover each one of a pair of the plurality of openings in an intermediate portion of the boiler door so that predetermined selective access can be provided to the chamber of the boiler through the first and second door panels.

A method for retrofitting a boiler in accordance with the principles of the invention is provided. The method includes a first step of removing a front door of the boiler. An inside door of the boiler that covers an access opening to a chamber of the boiler is then removed. An existing gas manifold and insulation formed adjacent a gas manifold opening is removed. The existing gas manifold is then modified to a smaller predetermined dimension. The gas manifold opening is then reinsulated and the modified gas manifold is installed. Insulation is then installed around the outermost periphery of the access opening in the boiler chamber. A coupling flange having the same diameter as the access opening in the boiler chamber is positioned in the access opening so that the flange is supported in the chamber adjacent the access opening. A boiler door having a plurality of spaced aligned openings formed therein is then coupled to the chamber adjacent the access opening to cover predetermined portions of the access opening. A high efficiency burner is then coupled in the boiler door in a lower one of the plurality of openings in the boiler door so that the burner is in operational alignment with the modified gas manifold. First and second door panels are then pivotably coupled to the boiler door to selectively cover each one of a pair of the plurality of openings in an intermediate portion of the boiler door so that predetermined selective access can be provided to the combustion chamber of the boiler through the first and second door panels. With the boiler retrofit with a single door in accordance with the principles of this invention an air cavity that normally exists in a two door boiler compartment is eliminated so that the fuel and air mixture is managed more efficiently and a much more efficient boiler apparatus is provided.

BRIEF DESCRIPTION OF THE DRAWING

The details of the invention will be described in connection with accompanying drawing in which:

FIG. 1 is a perspective view of a boiler to be retrofitted in accordance with the principles of this invention.

FIG. 2 is a perspective cross-sectional view taken along lines 2-2 of FIG. 1 with parts broken away from a boiler to be retrofitted in accordance with the principles of this invention.

FIG. 3 is a perspective cross-sectional view with the front door of a boiler being retrofitted, removed in accordance with the principles of this invention.

FIG. 4 is a coupling flange used in retrofitting the boiler in accordance with the principles of this invention.

FIG. 5 is a boiler having an inside door of the boiler being retrofitted, removed and the coupling flange mounted to the front of a boiler during retrofitting of the boiler in accordance with the principles of this invention.

FIG. 6 is a boiler having a retrofitted access door mounted to a front of the boiler during retrofitting of the boiler in accordance with the principles of this invention.

FIG. 7 is a boiler having a high efficiency burner mounted to a retrofitted access door of the boiler during retrofitting of the boiler in accordance with this principles of the invention.

FIG. 8 is a front end view of a retrofitted boiler showing a pair of door panels, pivotably mounted to cover openings in the front of the retrofitted access door of the boiler, in a closed configuration in accordance with the principles of this invention.

FIG. 9 is a front end view of a retrofitted boiler showing a pair of access door panels, pivotably mounted to cover openings in the front of the retrofitted access door of the boiler, in an open configuration in accordance with the principles of this invention.

FIG. 10 is perspective cross-sectional view of a retrofitted boiler having the access door panels, pivotably mounted adjacent the front of the boiler, in an open configuration in accordance with the principles of this invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring to FIGS. 1, 2 and 3 a boiler, generally designated, by the numeral 10 is provided. The boiler 10 is provided with an outer shell; generally designated, by the numeral 12 having a longitudinally extending opening or chamber 14 formed therein, (FIG. 2) an end wall 16 and a front or outside door 18, pivotably mounted to the chamber 14 to open and close. The chamber 14 is provided with an access opening 20 at an end thereof adjacent front the door 18. The chamber 14 is provided with baffle plates (not shown), a combustion cylinder 24 and a plurality of boiler fire tubes 26 all aligned therein in a well known manner to facilitate the normal operation of the boiler 10.

The front door 18 of the boiler 10 is provided with an upper opening 28 in which a standard boiler fan 30 is mounted and a lower opening 32 for supporting a standard boiler burner therein (not shown). The boiler 10 is also provided with an inside door 34 (FIG. 3), pivotably mounted to the chamber 14 to open and close, which is spaced from and aligned with the front door 18. An opening 36 formed in the inside door 34 is aligned with the opening 32 in the front door 18 so that the inside door is coupled over the access opening 20 of the boiler chamber 14. An air cavity 38 commonly referred to as the windbox, is formed between the front doors 18 and inside door 34 of the boiler 10 (FIG. 2). The air cavity 38 provides an area in which air can be generated by the fan 28 to interact with the burner and provide the fuel and air mixture needed to operate the boiler 10.

As illustrated in FIGS. 3 and 5 through 7, the boiler is also provided with a standard gas manifold or refractory ring 40 having an opening 42 formed therein. The gas manifold 40 is coupled over an opening 44 in the combustion cylinder 24 for allowing operational engagement with the combustion cylinder to facilitate normal boiler operation.

When retrofitted the boiler 10 the front door 18 of the boiler is removed. Once this is done the inside door 34 of the boiler that covers the access opening 20 to the boiler chamber 14 is then removed (FIG. 5). The gas manifold 40 and insulation 46 around and between the openings 42 and 44 is then removed to allow the gas manifold 38 to be reduced dimensionally, that is, in length and diameter, when necessary, to an the extent needed to form a modified gas manifold 48 (FIG. 5) that will fit in a retrofitted door compartment of the boiler. Once this is done the gas manifold opening 42 is reinsulated with insulation 50 and the modified gas manifold 48 can be installed over the opening 44. With the modified gas manifold 48 installed insulation 52 can be installed around the outermost periphery 54 of the access opening 20 in the chamber 14. The insulation may be, for example, a flexible medal gasket with special fiber installation that would eliminate leaks from inside the chamber 14.

Referring to FIG. 4, a cylindrically shaped coupling flange, generally designated, by the numeral, 60 is installed. The coupling flange 66 is designed specifically to facilitate the retrofitting process and is provided having a plurality of coupling apertures 62, a plurality of openings 64 and an aperture 66 formed therein. The coupling flange 60 has the same diameter as the outer periphery 54 of the access opening 20 of the chamber 14. The coupling flange 60 is supported in the access opening 20 over the insulation 52 around the outer periphery 54 of the boiler access opening 20 so that the flange can be coupled to the chamber 14 adjacent the access opening.

Once the flange 60 is installed, a boiler door, generally designated, by the numeral 68 (FIG. 6 and FIG. 7) is coupled to the chamber 14. The boiler door 68 is provided having a plurality of coupling apertures 70, a pair of openings 72 formed in an intermediate portion thereof, and an opening 74 formed in and aligned under the openings 72 in a lower portion of the door. The boiler door 68 is couplable to the chamber 14 adjacent the access opening 20 to cover the opening 64 in an upper portion of the coupling flange 60 and cover predetermined lower portions of the openings 64 in the flange. The boiler door may be coupled to the chamber 14 by bolts 76 (FIG. 7) or any number of other well known arrangements utilizing the coupling apertures 70.

A high efficient burner 80 which includes a fan and air manager build in, which creates a much higher level of efficiency in the fuel and air burner mixture, is then coupled to the boiler door 68 (FIG. 7). The high efficiency burner 80 is coupled in the boiler door 68 in the opening 74 in the boiler door so that the burner is in operational alignment with the gas manifold 48. This of course facilitates the operation of the boiler.

Referring to FIGS. 8 through 10, first and second door panels 82 which are provided to cover each one of the pair of openings 70 in the boiler door 68 are then coupled to the door. The door panels 82 are pivotably coupled to the door 68 by arm assemblies, generally designated, by the numeral 84. The arm assemblies 84 are each provided with a first arm member 86 having a pivot member 88 formed thereon and a second arm member 90 having a pivot member 92. The arm member 86 is coupled to the door 68 by the pivot member 88 and the arm member 90 which is coupled to door 82 is coupled to the arm 86 by the pivot member 92. This allows the door panels 82 to be pivoted to a closed position to cover the openings 72 (FIG. 8) and an open position allowing access to the openings (FIG. 9). The pivot arm 92 allows the door panels 82 to be moved to a position parallel to the outer shell 12 of the boiler 10 as illustrated in FIGS. 9 and 10. The door panels 82 may also be provided with insulation 94 on the inside of the door panel and a handle 96 on the outside thereof. As a result predetermined selective access can be provided to the combustion cylinder 24 and fire tubes 26 in the chamber 14 of the boiler 10 through the first and second door panels 82 without having to disturb the door 68 of the boiler 10.

With the boiler 10 retrofit with the single door 68 in accordance with the principles of this invention the air cavity 38 is eliminated. Additionally, the problems associated with the size and weight of the two doors is eliminated, and easier boiler access is provided. Still further, a higher level of efficient in the fuel to air mixture of the boiler is achieved and a much more efficient boiler apparatus is provided.

It should be further understood that various changes and modifications can be made to the invention without departing from the spirit of the invention as defined in the claims. 

1. A retrofitted boiler apparatus including: a boiler chamber having a longitudinal extending opening formed therein; an internal combustion cylinder aligned in the boiler chamber; a plurality of fire tubes surrounding the combustion cylinder; a coupling flange coupled in a frontmost portion of the opening in the boiler chamber; a door having a pair of spaced aligned openings formed in an intermediate portion thereof and an opening formed in a lower portion thereof, couplingly aligned adjacent the coupling flange in the chamber; means aligned in and coupled to the coupling flange in the lower opening in the door for directing a predetermined fuel and air mixture into the boiler chamber to form hot combustion gases in the combustion cylinder so that the fire tubes are activated to facilitate the operation of the boiler; and cover means pivotably mounted to the door for selectively covering each one of the pair of openings formed therein to provide selective access to the boiler chamber.
 2. A retrofitted boiler apparatus as defined in claim 1 wherein the coupling flange includes a plurality of spaced aligned openings formed therein.
 3. A retrofitted boiler apparatus as defined in claim 2 wherein the door cover means includes: a first door panel for selectively covering one of the pair of openings in the door; and a second door panel for selectively. covering the other one of the pair of openings in the door.
 4. A retrofitted boiler apparatus as defined in claim 3 wherein the door cover means further includes: a first arm member; a first pivot member coupled to the first arm member; a second arm member; and a second pivot member, the first arm member being coupled to each door panel by the first pivot member and the second arm member being coupled to each door panel and then to the first arm member by the second pivot member so that each door panel can be pivoted to a closed position and each door panel can pivoted to an open position.
 5. A retrofitted boiler apparatus as defined in claim 4 wherein the first and second door panels include an insulation member coupled to an inside surface thereof and an access handle coupled to an outside surface thereof.
 6. A retrofitted boiler apparatus as defined in claim 5 wherein the coupling flange has the same diameter as the boiler chamber and includes a plurality of coupling openings formed around the periphery thereof.
 7. A retrofitted boiler apparatus as defined in claim 6 wherein the door further includes: a plurality of coupling openings aligned with the coupling flange; and means for engaging the coupling openings in the door and flange to facilitate coupling of the door to the boiler chamber.
 8. A method for retrofitting a boiler apparatus including the steps of: removing a first door of the boiler; removing an inside door of the boiler that covers an access opening to a chamber of the boiler; removing an existing gas manifold and the insulation on a gas manifold opening; modifying the existing gas manifold to a predetermined smaller dimension; reinsulating the manifold opening and installing the modified gas manifold; installing insulation around the outermost periphery of outermost portions of the access opening in the boiler chamber; supporting a coupling flange having a plurality of openings formed therein in the access opening of the boiler so that the coupling flange is aligned in the chamber adjacent the access opening; coupling a boiler door, having a pair of spaced aligned openings formed in an intermediate portion thereof, and an opening formed in a lower portion thereof to the chamber adjacent the access opening to cover portions of the plurality of openings in the coupling flange; coupling a high efficiency burner in the lower opening in the boiler door so that the burner is in operational alignment with the modified gas manifold; and pivotably coupling a cover member to the boiler door to selectively cover the intermediate openings in the boiler door so that predetermined selective access can be provided to the combustion chamber through the cover member.
 9. A method for retrofitting a boiler apparatus as defined in claim 8 wherein the coupling flange includes a plurality of spaced aligned openings formed therein.
 10. A method for retrofitting a boiler apparatus as defined in claim 9 wherein the door cover means includes: a first door panel for selectively covering one of the pair of openings in the door; and a second door panel for selectively covering the other one of the pair of openings in the door.
 11. A method for retrofitting a boiler apparatus as defined in claim 10 wherein the door cover means further includes: a first arm member; a first pivot member coupled to the first arm member; a second arm member; and a second pivot member, the first arm member being coupled to each door panel by the first pivot member and the second arm member being coupled to each door panel and then to the first arm member by the second pivot member so that each door panel can be pivoted to a closed position and each door panel can pivoted to an open position.
 12. A method for retrofitting a boiler apparatus as defined in claim 11 wherein the first and second door panels include an insulation member coupled to an inside surface thereof and an access handle coupled to an outside surface thereof.
 13. A method for retrofitting a boiler apparatus as defined in claim 12 wherein the coupling flange has the same diameter as the boiler chamber and includes a plurality of coupling openings formed around the periphery thereof.
 14. A method for retrofitting a boiler apparatus as defined in claim 13 wherein the door further includes: a plurality of coupling openings aligned with the coupling flange; and means for engaging the coupling openings in the door and flange to facilitate coupling of the door to the boiler chamber. 